Method of manufacturing simulated fur of acrylic composite fiber



YAsUo ooNlsl-n ETAL 3,477,109 METHOD OF MANUFACTURING SIMULATED FUR OF ACRYLIC COMPOSITE FIBER 2 sheets-sheet 1 Nov. l 1, 1969 Filed Nov. '4, 196e AQS @bmx 4 Enz/Jemig?? ("5) Nov. 11, 1969 YASUO OON|5H| ETAL 3,477,109

' METHOD OF MANUFACTURING SIMULATED FUR OF `ACRYLIC COMPOSITE FIBER Filed Nov. 4, 1966 2 Sheets-Sheet 2 United States Patent O U.S. Cl. 26--2 Claims ABSTRACT F THE DISCLOSURE A method of treating simulated fur consisting of.

acrylic composite fibers, comprising subjecting said simulated fur to temperatures in the range of 50-120 C. in the presence of moisture so as to cause the fibers to become deformed, applying friction to the surface of said simulated fur so as to form a brushed surface, and heating the resultant product at a temperature of 60-90 C. to form simulated fur having interlaced fibers.

This invention relates to a method of brushing simulated fur of textile material, and, more particularly, to a method of brushing a simulated fur made from a spun yarn. The spun yarn is either made of an acrylic composite fiber having three-dimensional coil crimps (hereinafter referred to as acrylic composite fiber) or composed of two or more fibrous components, one of which is said acrylic composite fiber, the other components being selected from the class consisting of thermoplastic synthetic fibers, regenerated cellulosic fibers, and natural fibers including wool.

The object of the invention is to provide a method of brushing a simulated fur of acrylic composite fiber which comprises the steps of applying a light friction to the surface of the simulated fur `at suitable temperature and humidity to produce a brushed effect on said surface and, then, stabilizing the brushed effect so produced.

A method for brushing simulated fur of wool is already known, and the generally accepted advantages of brushing include:

(1) Reducing the fall-out of the fiber tufts.

(2) As Aformed nap prevents further brushing, so its original configuration orfeel keeps its endurance.

(3) Existence of nap conceals lthe ground or base fabric; and

(4) Warmth retention is increased.

One of l'the principles involved in the brushing ofthe simulated fur of wool is the utilization of the milling character of wool fiber. A p

The present invention utilizes the tendency of otherwise uncrimpable acrylic composite fiber having no milling character to have its apparent 2 softening point lowered within a certain temperature range lin the presence of moisture and, accordingly, become deformed in the direction of external forces at lower temperatures even when said forces are of a comparatively minor order, and at the same time, in accordance with the invention, the individual filaments which form the simuorder, and at the same time, in accordance with the inlated fur are interlaced as its latent three-dimensional coil crimps are developed.

The present invention will be described in more detail partly by referring to the accompanying drawings wherein:

FIG. 1 is a diagram showing the strength and elongation curves of acrylic composite fiber;

FIG. 2 is a diagram showing the temperature-initial Youngs modulus curves of acrylic composite fiber;

3,477,109 Patented Nov. l1, 1969 "ice FIG. 3 is a schematic diagram showing a brushing apparatus useful in carrying out the present invention;

FIG. 4 is a supporting pin device adapted to feed the man-'made fur to be brushed;

FIG. 5 is a sketch showing the rubbery element of thei brushing apparatus for use in brushing operation; an

FIG. 6 is a schematic perspective view of a rotary drum dryer.

To illustrate the point, Table 1 and FIGS. 1 and 2 show how the thermoplasticity of acrylic composite fiber is lowered in the presence of moisture.

TABLE 1.-PROPERTIES oF ACRYLIC FIBER UNDER DRY .HOT OR WET HOT CONDITIONS (S-DENIER ACRYLIC FIBER) Heat treatment Dry Wet Properties Strength, Strength,

g./d. percent g./d. ,percent Temperature, C.:

It will be apparent from both Table 1 and FIGS. 1 and 2 that the initial Youngs modulus of acrylic composite ber tends to become lowered as the treating temperature is increased and that, as a result, the fiber is readily deformed by external forces even when the CJD forces are of a comparatively minor order; In addition, the above table and said figures also reveal'clearly that as compared with the dry hot conditions, the deformation of the fiber is induced at much lower temperatures when it is heat-treated in the presence of moisture. As shown in FIG. 2, when the fiber is subjectedv to forces of approximately identical magnitude, its degree of deformation is substantially great at C. or higher under dry conditions, but similar degree of deformation is vobserved at temperatures as low as 50 C. when the heat-treatment is carried out in the presence of moisture. Thus, if a simulated fur manufactured from acrylic composite fiber at temperatures above 50 C. and in the presence of moisture is brushed lightly, the fiber is readily deformed as it is brushed andthis deformation cooperates with its three-dimensional coil crimps developed in the acrylic composite fiber to have them interlaced more intimately -with each other and, accordingly produce a rich nap. l When a simulated fur is made of an acrylic/composite ber having latent three-dimensional coil lcrimps (such product being well-known in the art), it is necessary' to have the latent three-dimensional 'coil crimps preliminarily developed by subjecting the fiber to the temperature of C. or higher in the presence of moisture either at the time of the brushing operation orat some step prior to said operation. y

In carrying out the brushing operation in which the simulated fur is subjected to an external force' of minor order in the presence of moisture at suitable temperatures it has been found to be advantageous to employ a brushing device 4 in FIG. 3 which is imparted with areciproeating or circular motion as indicated by the arrows, consisting `of a rubbery element having a corrugated surface, and a supporting device carrying a multiplicity of needles standing erect over its surface, these devices being so arranged that the simulated fur placed on said supporting device is constantly rubbed against by said rubbery element. l The simulated fur which has been brushed in the above manner has its filaments which formpthe simulated fur, bent, even if the external force imparted is of a comparatively small magnitude, and to correct this disadvantage and improve the value of the product, an operation is required at the drying step subsequent to the brushing operation to restore the filaments into the original erected position. To attain this effect, we have also found that when the simulated fur is put in a rotary drum dryer, for instance, with its brushed surface facing the center of the drum and the drum is driven for a suitable pen'od of time at elevated temperatures (higher than 60 C.), the filaments at and near the base of the fiber are erected, yielding a finished fur of high marketability.

Since the invention makes use of acrylic composite fiber having three-dimensional coil crimps, there are realized the following advantages over the simulated furs made of the conventional thermoplastic synthetic fibers. The filaments are more readily interlaced in the brushing operation, the interlaced configuration is highly resistant to change, and the hand or feel of the brushed surface is improved. Moreover, the fur is more elastic since the nap contains filaments having three-dimensional coil crimps. There are also additional benefits of improved warmth-retention and better concealment of the base fabric. It will thus be apparent that the simulated fur of the present invention is considerably superior to the fur prepared from mechanically crimped acrylic fiber of the conventional type.

This invention may be successfully carried into practice, using not only the unshrinkable acrylic composite fiber but also the so-called bulky acrylic composite fiber having a residual ability to shrink. Furthermore, a still improved stere effect may be had if the unshrinkable acrylic composite fiber is used in combination with the shrinkable acrylic composite fiber. The present invention may also be applied to the manufacture of simulated fur made of a blend of acrylic composite fiber and other fiber selected from the group consisting of natural fibers such as wool, regenerated fibers, and thermoplastic fibers including mechanically or two-dimensionally crimped acrylic fiber.

The term acrylic composite ber as used throughout this specification and the claims appended hereto means Ia fiber in which two or more acrylic copolymers having different thermal behaviors are eccentrically arranged along its length and which has three-dimensional coily crimps developed by virtue of said different thermal behaviors, said acrylic polymers being the copolymers containing acrylonitrile, with the other component or components of the copolymers being selected from the group consisting of the unsaturated compounds copolymerizable with a-crylonitrile, typical examples of said compounds including vinyl acetate, vinly pyridineacry lates, methacrylates, vinyl chloride, vinylidene chloride, allylsulfonic acid, metharylsulfonic acid, styrenesulfonic acid and the like. Such acrylic composite fibers are well known in the art so that no further detailed explanation is necessary. v

This invention will be further described in detail by way of the following examples, it being understood that the invention is by no meansl limited thereto.

Example 1 50 parts by weight of acrylic composite fiber, 3 denier X cut-length 76 mm. are blended with 50 parts by weight of regular acrylic fiber 5 denier x cut-length 31 mm., and is spun as blended single yarns which have worsted count 7s and twist value per meter of 220, to prepare a tufting material. On the other hand, from 100% cotton fibers, a ground or base fabric which has 1/2 dobby weave, 72 warps x 6-2 wefts construction and, said warp and weft have cotton count 30s and 7s respectively, is prepared. Both materials are fed to a machine, and fabricated as a simulated fur fabric. The preferred stitch for this tufting operation is about 12 inches. The tufting material is dyed with a wince dyer and, then, the tufts are raised by tigering. The preferred tuft-raising frequency is 2 to 3 cycles, with the height of the tufts ranging from 5 to 20 mm., and preferably from 12 to 18 mm. The tufts are then shorn two or three times so as to make the tufts of uniform length. As for the height of the tufts of the simulated fur, 5 mm. or less is insufficient to let the filaments be interlaced, as the fur is subsequently brushed, while 20 mm. or more is excessive, for such long filaments tend to lie down flat, thus making it diflicult to interlace them. The simulated fur prepared in the above manner is fed to an equipment shown in FIG. 3, through which the fur 1 travels in the direction of the arrow. The fur is sprayed at position 2 (as depicted in FIG. 3) with steam or hot water at 50 C. to 100 C.

If the temperature is below 50 C., the fiber will not adequately be softened, while the treatment at 100 C. or higher will prove too costly. On this heat-treatment, the simulated fur of acrylic composite fiber is temporarily softened, whereby the brushing operation is facilitated. The traveling speed of the fur through the machine is set at about 1 to 1.5 meters per minute. Indicated by the reference numeral 3 is an expander device which grips the simulated fur at both longitudinal edges in such a manner that the fur is spread, uncrumpled, and flattened, and feeds the fur to a rotary supporting device 5 which is provided with a multiplicity of stainlesssteel pins as illustrated in FIG. 4. The device 5 causes the simulated fur to travel in the direction of the arrow and the above-mentioned pins extending through the fur from the reverse side support the fur near the roots of its tufts. The surface of the simulated fur supported by said pins is held in intimate contact with a rubbery brushing element 4, which is imparted with a reciprocating motion so as to cause the raised filaments of the fur to be interlaced to produce a brushed surface. The brushing device 4 has a rubber hardness of about 90 degrees, (measured by Shimadzu Hardness Tester: Shimadzu Seisakusho Ltd.) being principally comprised of a hard rubber element of the shape illustrated in FIG. 5. When the rubber friction element is held in intimate contact with the surface of the simulated fur and, as such, is given either a reciprocating motion or a circular motion, the resulting vibration and friction causes the tufts of the fur to be interlaced to yield a brushed surface. In carrying out the brushing operation by means of the brushing device illustrated and described hereinbefore, it is also possible to provide said supporting device 5 if required, with an auxiliary heating apparatus 6 to -make the brushing operation easier. The amplitude of said reciprocating motion or the diameter of the circular motion of the brushing device may be altered between 0 and about 10 centimeters to form the desired configurations and` measurements of tufts. The simulated fur,

Vwhich has thus lbeen brushed by .a circular motion of e.g. -200 cycles per minute, is then placed in -a rotary drum dryer,'typically illustrated in FIG. 6, with itsbrushed side facing the center of the dryer. The drying temperature is 75 C.-90 C., and the drum is driven at the rate of '8-10 turnsveach 10 seconds, the rotation being reversed every 10` seconds. The fur is dried in about 30 seconds and, then, allowed to cool down to 60 C., at which temperature it is taken out. The fur fabric produced by the process described above, not only yields adequate configurations and measurementsv of tufts, but also ensures that the fibrous structure near the roots of the tufts will be sufiiciently erected, thereby Agiving a simulated fur rich in nap and high in marketability.

` Example 2 `are blendedwith 50 parts by weight of acrylic composite fiber, 5 denier X cut-length 51 mm., both of said fibers having been dyed in loose condition. This material is processed in the same manner as Example 1 (though the dyeing operation with the Wince dyeing machine is not required) to obtain a simulated fur rich in nap and high in marketability. The base fabric in this example has the same structure and materials as in Example l.

Example 3 To prepare a tufting material, 50 parts by weight of acrylic composite fiber having latent three-dimensional coil crimps, 3 denier x cut-length 76 mm., are blended with 50 parts by weight of similar fiber, 5 denier x cutlength 51 mm. The base fabric is the same as in Example 1. After a tufting operation which is carried out in the same manner as in Example 1, the tufts are raised by means of tigering. The height of the raised tuft is 5-20 mm. and, preferably, 12-18 mm. The product with its tufts so raised is treated with water vapor at 90 C.- 125 C. for 5-l0 minutes, whereby the latent threedimensional coil crimps are completely developed. After shearing and subsequent operations, which are carried out in the same manner as in Example 1, there is obtained a simulated fur of high marketability and rich in nap.

Example 4 60 parts by weight of acrylic composite liber, 3 denier x cut-length 76 mm. are blended with 40 parts by weight of acrylic ber composed of 40 parts by weight of acrylonitrile and 60 parts by weight of vinyl chloride to prepare a tufting material. The base fabric in this example is the same as in Example 1. This material is processed in the same manner as in Example 1 to prepare a brushed simulated fur of high marketability and rich in nap.

Example 5 60 parts by weight of acrylic composite fiber with its three-dimensional coil crimps remaining partly latent, 3 denier x 76 mm., are blended with 40 parts by weight of acrylic fiber composed of 60 parts by weight of acrylom'trile and 40 parts by weight of vinyl chloride, 7 denier x 51 mm., to prepare a tufting material. Using this material, a simulated fur is prepared by the same sequence of spinning, preparation of base fabric, tufting, dyeing, tuft raising, and shearing as described in Example 1. The fur is then fed to the equipment illustrated in FIG. 3. At the position 2 in FIG. 3, the fur is heattreated by saturated water vapor at 120 C., whereby its latent three-dimensional coil crimps are completely developed. Thereafter, the product is processed in the same manner as in Example 1 to obtain a simulated fur of high marketability and rich in nap.

Example 6 50 parts by weight of acrylic composite ber, 5 denier x cut-length 51 mm. are blended with 50 parts by weight of wool (quality No. 70), and using this tufting material, a simulated fur is prepared in the same sequence CTI of spinning, preparation of base fabric, tufting, dyeing, tuft raising, and shearing as described in Example 1. The simulated fur is then fed to the equipment illustrated in FIG. 3. At the position 2, the fur is sprayed with hot water at 95 C. and is transferred to the brushing device, where the surface of the simulated fur is supported from its reverse side by the supporting pincarrying element shown in FIG. 4. In this brushing device, the simulated fur is brushed in a circular motion (diameter 5 cm.; 150 cycles per minute). The brushing element consists principally of urethane rubber (hardness: 9'0 degrees measured by Shimadzu Hardness Tester; Shimadzu Seisakusho Ltd.) as illustrated in FIG. 5. The fur is then placed in the rotary drum-type dryer of FIG. 6, where it is dried at 80 C. for 30 minutes and, then, allowed to cool down to about C. The above procedure yields a simulated fur having a fluffy nap.

What is claimed is:

1. A method of treating simulated fur prepared from spun yarn comprising acrylic composite fibers having latent coil crimps, which comprises heating the simu lated fur to a temperature of 50 C.120 C. in the presence of moisture, imparting a frictional force to the surface of the simulated fur vto obtain a brushed surface, placing the simulated fur in a rotary drum dryer with the brushed surface facing the center thereof and stabilizing the fur therein at a temperature of 60-90 C.

2. A method as in claim 1 wherein the frictional force is imparted to the surface of the simulated fur in a reciprocating motion.

3. A method as in claim 1 wherein the frictional force is imparted to the surface of the simulated fur in a circular motion.

References Cited UNITED STATES PATENTS 161,588 4/1875 Bishop 26-27 1,797,754 3/ 1931 Bronander 26-27 1,889,902 12/1932 Moore 26-2 1,915,106 6/ 1933 Shuttleworth 26-2 1,917,555 7/ 1933 Shuttleworth 26-2 1,953,883 4/1934 Knowland et al. 26-2 1,975,466 10/ 1934 Knowland et al. 36-2 3,010,179 11/1961 Thal 28--72 3,293,723 12/ 1966 Evans 28-72 3,350,872 ll/1967 Gorrafa. 3,330,895 7/ 1967 Fujita et al 28-72 FOREIGN PATENTS 793,699 4/ 1958 Great Britain.

ROBERT R. MACKEY, Primary Examiner Us. C1. X.R. 

